Section 7

DIAGNOSTIC TESTS

4.If no movement is seen in Step 3 remove the con- trol panel cover. Verify the six pin connector (J2) on the Printed Circuit Board is seated properly, remove the connector and then replace it and test again. Verify the dip switches are correctly set.

NOTE: The dip switches on the Printed Circuit Board are factory set in the “OFF” or DOWN posi- tion. Refer to Figure 5.2 on Page 22.

5.If problem continues remove six pin connector (J2) from Printed Circuit Board. Set Volt meter to measure ohms. Carefully measure from the end of the six pin harness as follows:

BLACK

Test 4 – Fixed Excitation Test/Rotor

Amp Draw

DISCUSSION:

The fixed excitation test consists of applying bat- tery voltage (12 VDC) to the Rotor windings. This allows that portion of the excitation circuit between the Voltage Regulator and the Rotor (including the Rotor itself) to be checked as a possible cause of the problem. When battery voltage is applied to the Rotor, the resulting magnetic field around the Rotor should induce a Stator power winding voltage equal to about one-half the unit’s rated output voltage.

BROWN

YELLOW ORANGE RED

EMPTY

RED TEST LEAD

BLACK TEST LEAD

2

6

0

13 13

VOLTAGE REGULATOR

Figure 7-2. Six Pin J2 Connector Wire Colors

NOTE: Press down with the meter leads on the connectors exposed terminals, do not probe into the connector.

a. Connect one meter lead to Red, connect the remaining test lead to Orange, approximately 10 ohms should be measured.

b. Connect one meter lead to Red, connect the remaining test lead to Yellow, approximately 10 ohms should be measured.

c. Connect one meter lead to Red, connect the remaining test lead to Brown, approximately 10 ohms should be measured.

d. Connect one meter lead to Red, connect the remaining test lead to Black, approximately 10 ohms should be measured.

e. Connect one meter lead to Red, connect the remaining test to the stepper motor case. No resistance should be measured (“Infinity” or Open).

RESULTS:

1.If the stepper motor fails any part of Step 5 replace the stepper motor.

2.If the stepper motor passes all steps replace the Printed Circuit Board.

15

 

JUMPER WIRE

22S

11S

FUSE HOLDER (F1)

4

WIRES 4 REMOVED FROM

 

 

4VOLTAGE REGULATOR

Figure 7-3. – Fixed Excitation Test, Step A

PROCEDURE:

1.Disconnect Wire 4 from the Voltage Regulator (VR). (Third terminal from the right side of VR).

2.Connect a jumper wire to Wire 4 and to the 12 volt fused battery positive supply Wire 15, located at the fuse (F1) holder (see Figure 7-3).

NOTE: During this test, Wire 15 must remain con- nected to the fuse (F1) holder.

3. Set the VOM to measure AC voltage.

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Generac Power Systems 5415, 5412, 5411, 5413 Test 4 Fixed Excitation Test/Rotor Amp Draw, Six Pin J2 Connector Wire Colors
Page 38 Page 40

5410, 5414, 5415, 5413, 5411 specifications

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